JP2006130715A - Trim material having undulated surface and its molding method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a trim material having an undulated surface constituted by molding an arbitrary undulated shape to the surface of a skin material at the same time during a process for integrally molding the skin material and a thermoplastic resin, and its molding method. <P>SOLUTION: After the skin material 1, which is produced by laminating a fabric 1a, a cushion layer 1b and a back base fabric 1c from a surface side, is set to the inside of a mold, a molten thermoplastic resin 3 is injected to mold the trim material wherein the skin material 1 and the thermoplastic resin 3 are integrated, a fabric, which has a difference in its heat shrinkage factor in its longitudinal and lateral directions and is prepared by welding the fabric 1a and the back base fabric 1c through the cushion layer 1b in a dot form at least at two points in the direction large in the heat shrinkage factor, is used as the fabric 1a. By this constitution, the fabric 1a is shrunk between the dot like welded parts 2 and 2 by the heat received from the molten resin at the time of injection of the molten thermoplastic resin in the mold so as to be biased in the direction large in the shrinkage factor to form recessed stripe patterns 4 to the surface of the skin material 1. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an interior material having undulations on a surface formed by simultaneously molding an arbitrary undulation shape on the surface of a skin material in a process of integrally forming a skin material and a thermoplastic resin, and a molding method thereof. .

  For example, as an automotive interior material such as a door trim, a material obtained by integrally molding a skin material and a thermoplastic resin has been widely used. In general, such an interior material is formed by injecting a molten thermoplastic resin after setting the skin material in a mold. On the other hand, the preferences of users and the like have recently diversified, and there is a demand for a leather-made skin material that is provided with a gathered pattern or uneven pattern like leather to bring out a high-class feeling.

Therefore, for example, as disclosed in Patent Document 1, a leather-like sheet-like material having a stretchable skin layer made of a polyurethane elastic body has been proposed, and attempts to meet various needs have been made. However, a technique for integrally providing a gather pattern or uneven pattern such as leather on the fabric skin material has not been completed, and in this case, there was only a method by post-processing. As a result, there are problems that the molding process becomes complicated, the productivity is inferior, and the cost increases.
JP-A-6-293117

  The present invention solves the conventional problems as described above, and in the process of integrally forming the skin material made of fabric and the thermoplastic resin, the undulating shape can be integrally formed on the surface of the skin material. An object is to provide an interior material having undulations on the surface and a forming method thereof, which can form undulation shapes of any design, and can further achieve a significant cost reduction with excellent productivity. It has been completed.

In order to solve the above problems, the present invention provides a skin material laminated with a fabric, a cushion layer, and a back base fabric from the front side in a mold, and then injects a molten thermoplastic resin to heat the skin material and heat. An interior material integrally molded with a plastic resin, wherein the fabric has a difference in the vertical and horizontal heat shrinkage ratios, and the fabric and the back base fabric have a large heat shrinkage ratio through the cushion layer. Two or more dots are welded in the form of dots, and the surface of the skin material receives heat from the molten resin when the molten thermoplastic resin is injected into the mold, so that the fabric is bonded between the dot-shaped welds. A first invention is an interior material having undulations on the surface, characterized in that a concave streak pattern formed by shrinking the fabric in a direction with a large heat shrinkage rate is formed.
Also, after setting the skin material with the fabric, cushion layer, and back base fabric laminated from the front side, mold the interior material by injecting the molten thermoplastic resin and integrally molding the skin material and the thermoplastic resin. The fabric has a difference in the vertical and horizontal heat shrinkage rates as the fabric, and the fabric and the back base fabric are welded in a dot shape at two points or more in the direction of the large heat shrinkage rate through the cushion layer. When the molten thermoplastic resin is poured into the mold, the fabric is shrunk in the direction where the thermal contraction rate of the fabric is large between the dotted welds due to the heat received from the molten resin. The second invention is a method for forming an interior material, characterized in that a dent streaks pattern is formed on the surface of the skin material.

  In the present invention, the fabric has a difference in the vertical and horizontal heat shrinkage rates, and the fabric and the back base fabric were welded in a dot shape at two points or more in the direction of the large heat shrinkage rate through the cushion layer. When the molten thermoplastic resin is poured into the mold, the fabric is shrunk in the direction where the thermal contraction rate of the fabric is large between the dot-shaped welds due to the heat received from the molten resin. Since the concave streak pattern is formed on the surface of the material, an undulated shape of an arbitrary design can be integrally formed on the surface of the skin material without post-processing as in the prior art.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows a case where the present invention is applied to an automobile door trim. FIG. 1 is a partially cutaway perspective view, FIG. 2 is a perspective view of a skin material, and FIG. 3 is a direction in which the shrinkage rate of the skin material is small. FIG. 4 is an enlarged cross-sectional view, and FIG. 4 is an enlarged cross-sectional view in a direction in which the shrinkage rate of the skin material is large.

  In the figure, 1 is a skin material in which a fabric 1a, a cushion layer 1b made of a foamed material such as urethane, and a back base fabric 1c made of a nonwoven fabric are laminated from the surface side, and 3 is a heat formed integrally with the skin material 1. It is a resin layer made of a plastic resin. In the present invention, the skin material 1 has a fabric 1a that has a difference in the vertical and horizontal thermal contraction rates, and the fabric 1a and the back base fabric 1c are arranged in a direction in which the thermal contraction rate is large via the cushion layer 1b. Two or more points are welded in a dot shape.

Here, the reason why the fabric 1a has a difference in the vertical and horizontal heat shrinkage ratio is that, as will be described later, a difference is caused in the vertical and horizontal heat shrinkage of the fabric 1a by receiving heat from the molten resin. This is because the dent streak pattern 4 is formed only in an arbitrary direction by using.
The heat shrinkage of the fabric 1a is caused by heat treatment under a situation where a tensile force called a final set is applied (a situation in which distortion is generated) for the purpose of adjusting the width of the fabric during the production of the original fabric. This is because the fabric 1a is thermally contracted when the heat received from the molten resin becomes equal to or higher than the final set temperature in the molding process of the interior material. Therefore, the greater the difference between the vertical and horizontal thermal contraction rates (difference in strain) of the fabric 1a, the clearer the dent streaks pattern 4 can be formed.
Specifically, for example, in the case of a knitted fabric, a fabric fabric may be formed with warp and weft having different heat shrinkage rates.

In addition, the fabric 1a and the back base fabric 1c are welded in the form of dots at two points or more in the direction with a large heat shrinkage rate via the cushion layer 1b, so that between the adjacent welded portions 2 and 2 The fabric 1a can be heat-shrinkable to form a clearer dent line pattern 4.
In the illustrated example, the dot-shaped welds 2 are regularly formed in a lattice shape, but can be formed in an arbitrary pattern such as a wave shape, a zigzag shape, or a spiral shape.

Next, the molding method of the interior material of the present invention will be described. After setting the skin material 1 in which the fabric 1a, the cushion layer 1b, and the back base fabric 1c are laminated from the front side in the mold, the molten thermoplastic resin is used. The point of integrally molding the skin material 1 and the thermoplastic resin by stamping mold molding that injects so-called injection molding or thermoplastic resin into the mold and then closes the mold and pushes the resin is that of the conventional interior material This is basically the same as the molding method.
In the present invention, the fabric 1a has a difference in the vertical and horizontal heat shrinkage rates, and the fabric 1a and the back base fabric 1c have two or more dots in the direction in which the heat shrinkage rate is large via the cushion layer 1b. What was welded in the shape is used. Thus, when the molten thermoplastic resin is injected into the mold, the fabric is biased in the direction in which the thermal contraction rate of the fabric 1a is large between the dot-shaped welded portions 2 and 2 due to heat received from the molten resin. It is characterized in that 1a is contracted to form a concave streak pattern 4 on the surface of the skin material.

That is, as shown in FIG. 3, in the direction in which the thermal contraction rate of the fabric 1a is small, even when the molten thermoplastic resin is injected into the mold and the heat receiving temperature is equal to or higher than the final set temperature, the distortion does not occur. Since it is small, the heat shrinkage is small and the shape is maintained as it is.
On the other hand, as shown in FIG. 4, in the direction in which the thermal contraction rate of the fabric 1a is large, when the molten thermoplastic resin is injected into the mold and the heat receiving temperature is equal to or higher than the final set temperature, the strain is large. Thermal contraction increases. At this time, since the fabric 1a and the back base fabric 1c are welded in the form of dots at two points or more in the direction in which the thermal contraction rate is large via the cushion layer 1b, the welding is performed between the adjacent welded portions 2 and 2. The fabric 1a shrinks with the section 2 as a partition, and a clear dimple pattern 4 having a depth d is formed on the surface of the skin material. In addition, since the part which does not have the welding part 2 does not have a division | segmentation and shrinks as a whole, a local dent is not formed and it does not become a dent streak pattern.
As a result, a clear dent streak pattern 4 with the adjacent welded portions 2 as a partition is formed in the direction in which the thermal contraction rate of the fabric 1a is large.

  As is clear from the above description, the present invention has a difference in the vertical and horizontal thermal contraction rates as the fabric 1a, and the fabric 1a and the back base fabric 1c have a thermal contraction rate via the cushion layer 1b. When two or more dots are welded in a large direction in the form of dots and a molten thermoplastic resin is injected into the mold, the fabric is formed between the dot-shaped welds 2 and 2 by receiving heat from the molten resin. Since the fabric 1a is shrunk in the direction in which the thermal contraction rate of 1a is large and the dent streaks pattern 4 is formed on the surface of the skin material, the undulating shape is formed during the normal molding process without post-processing as in the prior art Can be formed integrally. Further, by changing the pattern of the dot-like welded portion 2 or changing the direction of the skin material 1 set in the mold, an arbitrary dent streaked pattern 4 can be formed, and the width of the design as an interior material Can be expanded.

It is a perspective view which shows embodiment of this invention. It is a perspective view which shows a skin material. It is an expanded sectional view of the direction where the shrinkage rate of a skin material is small. It is an expanded sectional view in the direction where the shrinkage rate of the skin material is large.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Skin material 1a Fabric 1b Cushion layer 1c Back base fabric 2 Dot-shaped weld part 3 Resin layer 4 Recessed streaks pattern

Claims (3)

  An interior material in which a skin material in which a fabric, a cushion layer, and a back base fabric are laminated from the front surface side is set in a mold, and then a molten thermoplastic resin is injected to integrally mold the skin material and the thermoplastic resin, The fabric has a difference in the vertical and horizontal heat shrinkage rates, and the fabric and the back base fabric are welded in a dot shape at two points or more in the direction of the large heat shrinkage rate through the cushion layer. The surface of the skin material shrinks in a direction in which the thermal contraction rate of the fabric is large between the dot-shaped welds due to heat received from the molten resin when the molten thermoplastic resin is injected into the mold. An interior material having undulations on the surface, wherein the resulting dent streaks are formed.   After setting the skin material with the fabric, cushion layer, and back base fabric laminated from the front side in the mold, the molten thermoplastic resin is injected and the skin material and the thermoplastic resin are integrally molded. In addition, the fabric has a difference in heat shrinkage between the length and breadth, and the fabric and the back base fabric were welded in a dot shape at two points or more in the direction in which the heat shrinkage is large through the cushion layer. When the molten thermoplastic resin is poured into the mold, the fabric is shrunk in the direction where the thermal contraction rate of the fabric is large between the dot-shaped welds due to the heat received from the molten resin. A method for forming an interior material, comprising forming a dent streak pattern on a material surface. The molding method according to claim 2, wherein heat received from the molten resin is equal to or higher than a temperature at the time of final setting of the fabric.

Images